Carton and blank for making same



' April 14, 1970 A M. T. FARQUHAR 3,506,181

CARTON AND BLANK FOR MAKING SAME Filed March 25, 1968 v 3 Sheets-Sheet 1 FIG-l "I00 IOI" I02 I05 H2 56 7O MELVILLE r al $532k BY MM,

HIS ATTORNEYS April 14, 9 M. T. FARQUHAR 3,506,181 I CARTON AND BLANK FOR MAKING SAME 3 Sheets-Shet z Filed March 25, 1968 INVENTOR. MELYILLE T. FARQUHAR "BY GM P 3 HIS ATTORNEYS M. T. FARQUHAR CARTON AND BLANK FOR MAKING. SAME ,April 14, 1970 Filed March 25. 1968.

3 Sheets-Sheet 3 FIG-4 .mHHHU) 45 43 FIG-5 "FIG-6 R H O U MO m mF T E L H w E M HIS ATTORNEYS United States Patent CARTON AND BLANK FOR MAKING SAME Melville T. Farquhar, Bon Air, Va., assignor to Reynolds Metals Company, Richmond, Va., a corporation of Delaware Filed Mar. 25, 1968, Ser. No. 715,743 Int. Cl. B656 /10 US. Cl. 229-39 16 Claims ABSTRACT OF THE DISCLOSURE This disclosure relates to a carton and blank for making same wherein such carton is preglued and shipped and stored in a flattened condition and is easily set up by pushing against opposite edges of the flattened carton. The carton has a bottom wall defined by a plurality of interlocking flaps which are also preglued and constructed and arranged to assure that they will not become unfastened during set up of the carton and after placing a product therewithin.

BACKGROUND OF THE INVENTION Many products, such as food products, are packaged for storage and sale in cartons which have been preglued and maintained in a flattened condition until they are ready to be used. A particular carton of this type is readily set up merely by pushing opposite side edges of the flattened carton toward each other causing it to expand into a substantially tubular configuration and causing its bottom wall to be formed substantially automatically during the above-described pushing action. Each of the previously proposed cartons of this type has a bottom wall defined by a plurality of cooperating preglued extension flaps and each of such cartons is deficient because during the set up thereof the forces applied against such preglued extension flaps generally cause portions of the outer surface layers of such flaps which have glue applied thereagainst to delaminate from adjoining structure thereby releasing the associated flaps and making such carton unsuitable for placing a product therewithin. Further, even in those instances where the bottom wall of a present carton of this type is sufficiently strong to hold together during the set up process, it has been found that the construction thereof does not provide optimum structural strength whereby there is considerable waste due to failure of the bottom wall after a product has been placed therein.

SUMMARY This invention provides an improved preglued carton and an improved blank for making such a carton wherein the carton is generally stored and shipped in a flattened condition and readily set up for use merely by pushing against opposite side edges thereof to expand the carton and automatically form its bottom wall which is defined by a plurality of unique interlocking flaps which assure that such bottom wall retains its structural strength during set up and while containing a product within the carton.

Other details, uses, and advantages of this invention will become apparent as the following description of the embodiment thereof presented in the accompanying drawings proceeds.

BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings show a present preferred embodiment of this invention, in which FIGURE 1 is a perspective view of the improved carton of this invention showing such carton immediately after 3,506,181 Patented Apr. 14, 1970 it has been set up and with its top wall open to enable a product to be placed therein;

FIGURE 2 is a plan view of the carton of FIGURE 1 in its preglued flattened condition and prior to set up thereof;

FIGURE 3 is a fragmentary perspective view of the lower end portion of the carton of FIGURE 1 showing the action of the various extension flaps comprising the bottom wall of such carton upon urging oppositely arrafiged side edges of the preglued carton toward each of er;

FIGURE 4 is a fragmentary perspective view similar to FIGURE 3 and illustrating the extension flaps defining the bottom wall of such carton at a later stage of set up;

FIGURE 5 is a view looking normally upwardly toward the bottom wall of the carton of FIGURE 1;

FIGURE 6 is a fragmentary perspective view looking toward the left end portion, as viewed in FIGURE 4, of a full area extension flap comprising the bottom wall of the carton of FIGURE 1 and as viewed from the inside of such carton; and

FIGURE 7 is a plan view of the blank used to make the carton of FIGURE 1.

DESCRIPTION OF ILLUSTRATED EMBODIMENT Reference is now made to FIGURE 1 of the drawings wherein an exemplary carton of this invention designated generally by the reference numeral 20 is illustrated.

The carton 20- comprises a pair of oppositely arranged end walls 21 and 22, a pair of oppositely arranged side walls 23 and 24 suitably fastened to opposite side edges of the end walls, a bottom wall 25 defined by a plurality of extension flaps extending from the lower edges of the vertical walls 21-24 (in a manner to be subsequently described in detail), and a hinged top wall 26, which in FIGURE 1 is shown in an open position and has a closure or tuck flap 27 extending from the terminal end thereof.

The carton 20 also has a pair of backup flaps 31 and 32 extending from the top edges of end walls 21 and 22 respectively. The backup flaps 31 and 32 are adapted to be folded in position, in a known manner, prior to folding the top wall 26 thereagainst and inserting the closure flap 27 against the top inside surface of side wall 23 to close the carton 20 after placing a product therein.

The carton 20 is in the form of a preassembled or preglued carton which has its vertical walls 21-24 suitably fastened together and has its bottom wall 25 defined by a plurality of cooperating extension flaps wherein certain ones of such flaps are preglued and the construction and arrangement thereof is such that the carton may be easily set up or expanded from the flattened condition shown in FIGURE 2, merely by pushing oppositely arranged side edges thereof toward each other as by applying forces thereagainst essentially as shown by the arrows 35 and 36 in FIGURE 3 of the drawings.

As seen particularly in FIGURES 35 of the drawings the previously mentioned plurality of extension flaps defining the bottom wall 25 comprise a first extension flap 40 which extends from the lower edge 41 of side wall 23 and the flap 40 comprises a part of the outside surface of the bottom wall 25.

A second extension flap 43 extends from the lower edge 44 of the end wall 22 and the extension flap 43 is adhesively fastened as by glue, or the like, to the extension flap 40 as shown at 45. The extension flap 43 has a first fold line 46 extending thereacross which enables the extension flaps 40 and 43 to remain fastened together while folding the flaps 43 and 40 and their respective walls 22 and 23 substantially into a common plane.

The bottom wall 25 is also comprised of a third extension flap 50 which extends from the lower edge 51 of the side wall 24 and extension flap 50 has a full area substantially equal to the total area of the bottom wall 25 and the inside surface of the extension flap 50 defines the inside surface of the bottom wall 25. The extension flap 50 may be referred to as a full-area flap 50 at various locations later in this specification to enable an easier understanding of the cooperating relationship of the various extension flaps defining or comprising the bottom wall 25.

A fourth extension flap 54 extends from the lower edge 55 of end Wall 21 and the flap 54 has an integral glue tab 56 extending from its terminal end which is adhesively fastened or glued to the full-area flap 50 adjacent its near end portion. The extension flap 54 also has a second fold line 57 provided therein and extending thereacross so that with the glue tab 56 adhesively fastened to the extension flap 50, the flaps 54 and 50 and their respective walls 21 and 24 may be flattened or collapsed substantially in one plane and in the manner shown in FIGURE 2 of the drawings.

The extension flaps 40, 43, 50, and 54 are constructed and arranged so that upon pushing against the opposite end edges of the collapsed carton 20 such extension flaps are folded together automatically in a unique interlocking manner. Those extension flaps that have been preglued are constructed and glued together in a sufficiently strong manner and over sufliciently large areas that they will not become unfastened due to the forces applied to set up the carton 20. Further, the bottom wall 25 defined by the above described extension flaps has high strength and assures that a product carried within the carton 20 is contained and protected in the desired manner.

It will be noted from FIGURES 3-5 of the drawings that during the process of setting up the preglued collapsed carton 20, the end portion of extension flap 40 which adjoins end wall 21 has one corner portion 61 which extends beneath a portion of the extension flap 54 while another portion of extension flap 40 designated generally by the reference numeral at 62 and arranged adjacent the corner portion 61 extends outwardly of a portion 63 of the integral glue tab portion 56 of the extension fiap 54 to provide a strong interlocking action. This interlocking action not only relieves the tendency of the glue tab 56 to be pulled away from that portion of extension flap 50 adhesively fastened thereagainst but also securely holds in position that end portion of the fullarea flap 50 which adjoins end wall 21.

The integral glue tab 56 has a comparatively large area of substantially rectangular outline as will be readily apparent from FIGURES 5 and 7 of the drawings and the over all length thereof is such that a substantial part of one of its end portions and in particular its previously mentioned end portion 63 is sandwiched between the extension flaps 40 and 50. This sandwiching action together with its large glue area further assures that the extension flap is held even more firmly in position upon placing a product within the carton 20.

In the constructions illustrated, the extension flap 54 is subjected to comparatively higher loads and extension flap 54 has a weakened fold line 57 to enable such flap to be folded and the preglued carton 20 to be collapsed. This weakened line 57 tends to break the outer layers of the paperboard used to make the carton 20 along the line 57 and as Will be described in more detail later in this specification. Upon setting up the carton 20 any substantial breaking of surface layers along line 57 results in the inner layers of flap 54 arranged outwardly of fold line 57, and indicated generally by the reference numeral at 68 in FIGURE 5, tending to be pulled away to release the flap 54. However, once the terminal end of the fold line '57 is' reached a side edge of glue tab 56 is reached and there is an abrupt increase in the width of the inner layer that must be delaminated, if such delamination were to continue, due to the larger area provided by end portion 63 of glue tab 56. It has been found that the effect of this abrupt width increase is to prevent any further tendency for the flaps 50 and 54 to become separated, whereby the bottom wall 25 is further assured of being held together.

Each of the prior art cartons which is similar to the carton 20 also has a flap similar in function to flap 54 of carton 20 and such similar flap has a weakening or score line provided therein which is similar in function to score line 57; however, each of such prior art cartons does not have a large glue tab similar to tab 56 with its end portion 63 whereby once any delamination is started in a particular prior art carton its corresponding flaps are easily separated.

The extension flap 43 has a substantially trapezoidal outline having a 90 degree angle 65 defined at the junction of two of its sides and the fold line 46 is arranged so that it approximately bisects the angle 65. The extension flap 43 has an adhesive, such as glue, applied to an approximately trapezoidal terminal outer end portion thereof which fastens flap 43 to flap 40. Upon pushing the opposite side edges of the flattened carton 20 toward each other in the manner shown in FIGURE 3, the tendency is for the walls 23 and 24 to be moved away from each other by the interconnecting end walls 21 and 22 and simultaneously the extension fiap 40 is pulled by flap 43 so that it moves away from the side wall 23 against which it was previously flattened.

The extension flap 54 has a main portion 67 of substantially trapezoidal outline and the integral rectangular outline glue tab portion 56 extends from its terminal outer end. The glue tab 56 has an edge 70, see FIGURE 7, which is arranged in line with a nonparallel edge also designated by the numeral 70 of the trapezoidal portion 67 of extension flap 54. The rectangular glue tab 56 also has an edge 71, indicated by a dot-dash line for reference purposes only, which is common with one of the parallel side edges of the trapezoidal portion 67.

As seen particularly in FIGURE 5 the rectangular glue tab 56 has a length indicated at 74 which is greater than the length of the shorter one of the parallel sides of the trapezoidal portion 67 of extension fiap 54, and it will be seen that the end portion 63 of glue tab 56 is sandwiched between the flaps 40 and 50, in the manner previously described, during the set up of the carton 20. The fold line 57 provided in trapezoidal portion 67 extends from an inside corner 75 thereof to the outer end of the one parallel side edge of trapezoidal portion 67 which is positioned substantially diagonally thereacross, see FIGURE 5. Upon fastening the integral glue tab 56 in position against the full-area flap 50, the fold line 57 enables the extension flaps 54 and 50 and their respective walls 21 and 24 to be collapsed into a common plane.

The various fold lines provided in the carton 20 are generally formed utilizing suitable equipment, such as conventional scoring equipment, which in a high volume production operation the scoring blades thereof are urged against only one surface of a blank used to make carton 20.

However, it will be appreciated that with such scoring it is easier to fold the portions of material adjoining a particular score line in one direction about such score line and there is considerable resistance to folding in an opposite direction. All of the fold lines, except 46 and 57, provided in carton 20 facilitate easy folding of portions of the carton adjoining each fold line in an inward direction. However, as seen in FIGURES 3 and 4 of the drawings, the fold lines 46 and 57 provided in extension flaps 43 and 54 respectively, if formed in a similar manner, i.e., by scoring in a similar manner as the other fold lines of the carton, would provide resistance to collapse of the preglued carton 20. As'a' result of this and to enable, in effect, a reverse folding of flaps 43 and 54 along their fold lines 46 and 57, the fold lines 46 and 57 are preferably made in the form of cut-score lines. Each cut-score line 46 and 57 has a plurality of slits 76 aligned end-to-end and may be provided with suitable scoring between each pair of immediately adjacent slits. The cut-score lines 46 and 57 enable easy reverse folding in the manner which will be readily apparent from FIGURE 3.

The extension flap 40 has an outward extension indicated at 80 and a terminal outer edge 81 which is spaced apart from that part of the trapezoidal portion 67 of extension flap 54 which is normally held flatly against the outside surface of the full-area flap 50. The outward extension or width 80 of the extension flap 40 is such that it extends across roughly half of the width of the bottom wall 25 in the manner described previously.

The outer end portion of the extension flap 40 which is adapted to be folded against the rectangular glue tab 56 has an approximately rectangular cutout 83 provided therein and the cutout 83 assures easier folding of the various extension flaps defining the bottom wall 25 in position by not interfering with the folding of the end portion 63 of the glue tab therebeneath and thus precluding the possibility that the terminal outer edge 81 of the flap 40 might be wedged between the glue tab 56 and extension flap 50 to separate tab 56 from flap 50 by a wedging action. In fact, such a wedging action which is prevented by the improved cooperating extension flaps of the carton of this invention is prevalent and comprises a major deficiency in many similar cartons which have been proposed heretofore.

As previously mentioned, extension flap 50 is essentially a full-area flap which has only a small roughly rectangular cutout 87 provided therein in its corner portion which is arranged adjacent end wall 21 whereby flap 50 has an area substantially equal to the total area of the bottom wall 25. A full-area flap is provided for several reasons including the desirability of having a continuous surface to define the bottom wall of carton 20 and particularly in those applications where carton 20 is used to contain a food product such as ice cream, for example. Further, it is desired that the flap 50 be a full-area flap, otherwise with the carton normally shipped and stored in a flattened or collapsed condition there is a tendency for such carton to return to its collapsed condition once the forces exerted against its opposite side edges to set up the carton are relieved. This could create a problem during the filling of the carton 20 with an associated product. With a full-area flap 50, it will be seen that the flap 50 drops into a horizontal position once the carton 20 is set up and prevents the normal tendency of the carton to return to its collapsed condition, whereby the carton 20 may be easily filled and then sealed by folding the backup flaps 31 and 32 in position and closing the top wall 26 by inserting the tuck flap 27 in position in a known manner. I

The extension flap 50 is a full-area flap primarily for the reasons discussed above. However, by having such a full-area flap it will be appreciated that during the process of expanding or setting up the carton 20 in the manner illustrated in FIGURES 3 and 4 of the drawings there is a tendency for a corner 85 thereof which adjoins end wall 21 to drag across the end wall 21 as shown in FIGURE 6. In previously proposed cartons this type of dragging action is generally sufficient to cause some of the associated extension flaps to become unglued. This invention, however, solves this problem caused by dragging of a full-area flap by the construction and arrangement of the various extension flaps defining the bottom wall 25 and particularly by making the glue tab 56 of a comparatively large area and providing an interlocking action as previously described in detail.

Those extension flaps of the exemplary carton 20 defining bottom wall 25 which have been preglued are fastened together over comparatively large area portions, to help provide higher strength for bottom wall 25. By way of contrast, and as previously mentioned, prior art cartons have comparatively small glued areas which result in concentrated forces being applied against correspondingly small areas of the outer layers of such flaps which causes such small areas to start delaminating from adjoining structure in an easier manner. Once delamination of the outer layers of such prior art cartons is started it will generally continue until the associated flaps are completely unfastened, as previously explained.

The problem wherein a glued portion of an extension flap becomes severed away from an adjoining extension flap is aggravated particularly in those applications where the carton is made of paperboard which has been produced on a cylinder machine and generally referred to as cylinder board. In cylinder board the fibers thereof are deposited in a plurality of layers wherein the fibers in each layer are generally arranged in an aligned manner because of the manner in which the slurry, technically refered to as furnish, used to make the paperboard is deposited in position by the cylinder machine. This construction makes it easier to delaminate the layers of cylinder board which adjoin a glued area once a pulling force is applied thereagainst. Yet, cylinder board is comparatively inexpensive and is used extensively in carton constructions. By using the unique arrangement of the extension flaps comprising the bottom wall 25 of the carton of this invention a high strength construction is provided even while using cylinder board.

The carton 20 can be formed in any suitable manner and made from any suitable foldable material. It is preferably formed from the single piece blank illustrated in FIGURE 7 of the drawings. Blank 95 is made of paperboard, or the like, and may have one or both of its sides laminated with metallic foil, such as aluminum-containing metallic foil or the like, suitably colored, embossed, imprinted, or remaining plain, as desired.

The description of the blank will now proceed by describing primarily those structural portions which were not previously described in detail in connection with the description of the carton 20. However, where a detailed description was made in connection with the carton, such description will not be repeated in connection with the blank and corresponding component portions of the blank 95 will be designated by the same reference numeral as in the carton 20.

The blank 95 is suitably cut and scored and adapted to be assembled to define resulting carton 20 of this invention and comprises a pair of parallel score lines designated generally by the reference numerals 96 and 97 and defining the lateral extent in one direction, i.e., the height of the vertical walls 21-24. The score line 96 is a continuous line and is comprised of component portions 44, 41, 55, and 51 defining the lower edges of their respective walls 22, 23, 21, and 24.

The lateral extent or width of each of the walls 21-24 is defined by a plurality of parallel spaced'apart score lines 100, 101, 102 and 103 defining respectively end wall 22 extending outwardly of score line 100, side wall 23 extending between score lines 100 and 101, end wall 21 extending between score lines 101 and 102, side wall 24 extending between score lines 102 and 103, and a fastening flap 104 extending outwardly of score line 103. The flap 104 is adapted to be suitably fastened in position to the inside surface of the end wall 22 as by adhesive or glue and in a known manner, whereby upon fastening the flap 104 in position the resulting carton is in the form of a substantially tubular structure of rectangular peripheral outline and having open ends.

The extension flap 43 has suitable adhesive means such as glue applied on its end portion 66 and such glue is indicated at by a granular showing. In a similar manner the glue tab 56 has adhesive means such as glue applied thereagainst as shown at 112.

Thus, it is seen that the carton 20 is made from blank 95 and is preglued or preassembled by gluing the flap 104 against the inside surface of the end wall 22 and suitably gluing the extension flaps 43, 40, 54, and 50 together in the manner previously described to enable 7 such preglued carton 20 to be shipped and stored in the flattened configuration illustrated in FIGURE 2. The flattened carton 2 is set up or expanded for use by pushing against its opposite side edges in the manner previously described in connection with FIGURES 3 and 4 of the drawings. 4

It will be appreciated that the construction and arrangement of the various extension flaps comprising the bottom wall 25 of the resulting carton 20 is such that the glue tab 56 may be increased in area, as desired, so that additional blank material is not required. In particular, it will be noted from FIGURE 7 of the drawings, that both the width and the length of the glue tab 56 may be increased without requiring more blank material so as to enable provision of a fastening tab or glue tab as desired for the particular application and essentially as taught by this invention.

While present exemplary embodiments of this invention have been illustrated and described, it will be recognized that this invention may be otherwise variously embodied and practiced by those skilled in the art.

What is claimed is:

1. A carton comprising, a pair of end walls, a pair of side walls fastened to opposite side edges of said end walls, a plurality of cooperating extension flaps extending from the lower edges of said walls and cooperating to define a bottom wall for said carton, said extension flaps comprising, a first extension flap extending from one of said side walls and comprising a part of the outside surface of said bottom wall, a second extension flap extending from one of said end walls and being fastened to said first extension flap, a fold lhie in said second extension flap enabling said first and second flaps and their adjoining walls to be folded in a common plane Whiie securely fastened together, a third fuil-area extension flap extending from the other of said side walls and having an area substantially equal to the total area of said bottom wall, said third extension flap defining the inside surface of said bottom wall, a fourth extension flap extending from the other of said end wails, a glue tab provided as an integral portion of said fourth extension flap and heing fastened to said third extension iiap, said integral glue tab having an orerall length greater than half the width of said bottom wall to provide a comparatively large glue area, said integral glue tab comprising a substantially rectangular tab having an overall length such that an end portion thereof is sandwiched between said first extension flap and said full-area flap, and a second fold line in said fourth extension flap enabling said third and fourth extension flaps and their adjoining walls to be flattened in said common plane, said carton being preglued and shipped and stored in a flattened condition and easily set up 'by pushing opposite side edges of the flattened carton substantially toward each other, causing said extension flaps to be moved together in an interlocking manner to automatically define said bottom wall and cansing the outer corner of said full-area flap arranged adjacent said glue tab to drag across an end wall tending to unfasten said third and fourth extension flaps and the comparatively large glue area of said glue tab and interlocking arrangement of said extension flaps assure complete set up of said carton while providing a high strength bottom wall therein in which said extension flaps remain securely glued together.

2. A carton as set forth in claim 1 in which said first extension flap has an outward extension approximately equal to half the width of said bottom wall and said overall length of said integral glue tab is such that said end portion thereof is sandwiched between the terminal end portion of said first extension flap and said full-area flap.

3. A carton comprising, a pair of end walls, a pair of side walls fastened to opposite side edges of said end walls, a plurality of cooperating extension flaps extending from the lower edges of said walls and cooperating to define a bottom wall for said carton, said extension flaps comprising, a first extension flap extending from one of said side walls and comprising a part of the outside surface of said bottom wail, a second extension flap extending from one of said end walls and being fastened to said first extension flap, a fold line in said second extension flap enabling said first and second flaps and their adjoining walls to 'be folded in a common plane whiie securely fastened together, a third fuli-area extension flap extending from the other of said side walls and having an area substantially equal to the total area of said bottom wall, said third extension flap defining the inside surface of said bottom wall, a fourth extension flap extending from the other of said end walls, a g'tue tab provided as an integral portion of said fourth extension flap and being fastened to said third extension flap, said integral glue tab having an overall length greater than half the Width of said bottom wall to provide a comparatively large glue area, a second fold line in said fourth extension flap enabling said third and fourth extension flaps and their adjoining walls to be flattened in said common plane, and a fifth extension flap extending from the upper edge of one of said side walls and defining a top wall for said carton, said fifth extension flap having a tuck flap extending from its terminal end for closing said carton, said carton being pre-glued and shipped and stored in a flattened condition and easily set up by pushing opposite side edges of the flattened carton substantially toward each other, causing said extension flaps to be moved together in an interlocking manner to automatically define said bottom wall and causing the outer corner of said full-area flap arranged adjacent said glue tab to drag across an end wall tending to unfasten said third and fourth extension flaps and the comparatively large glue area of said glue tab and interlocking arrangement of said extension flaps assure complete set up of said carton while providing a high strength bottom wall therein in which said extension flaps remain securely glued together.

4. A carton comprising, a pair of end walls, a pair of side wails fastened to opposite side edges of said end walls, a plurality of cooperating extension flaps extending from the lower edges of said walls and cooperating to define a bottom wall for said carton, said extension flaps comprising, a first extension flap extending from one of said side walls and comprising a part of the outside surface of said bottom wall, a second extension flap extending from one of said end walls and being fastened to said first extension flap, a fold line in said second extension flap enabling said first and second flaps and their adjoining walls to be folded in a common plane while securely fastened together, a third full-area extension flap extending from the other of said side walls and having an area substantially equal to the total area of said bottom wall, said third extension flap defining the inside surface of said bottom wall, a fourth extension flap extending from the other of said end walls, a glue tab provided as an intergral portion of said fourth extension flap and being fastened to said third extension flap, said integral glue tab having an overall length greater than half the width of said bottom wall to provide a comparatively large glue area, and a second fold line in said fourth extension flap enabling said third and fourth extension flaps and their adjoining walls to be flattened in said common plane, said fourth extension flap having a main portion of substantially trapezoidal outline, said integral glue tab having a rectangular outline and having an edge arranged in line with a nonparallel edge of said trapezoidal main portion and an adjoining edge which is common with the outer parallel side edge of said trapezoidal main portion, and said rectangular giue tab having a length greater than the length of said one parallel side edge so that an end portion thereof isandwiched between said first extension flap and said fullarea flap, said carton being pre-glued and shipped and stored in a flattened condition and easily set up by pushing opposite side edges of the flattened carton substan tially toward each other, causing said extension flaps to be moved together in an interlocking manner to automatically define said bottom wall and causing the outer corner of said full-area flap arranged adjacent said glue tab to drag across an end wall tending to unfasten said third and fourth extension flaps and the comparatively large glue area of said glue tab and interlocking arrangement of said extension flaps assure complete set up of said carton while providing a high strength bottom wall therein in which said extension flaps remain securely glued together.

5. A carton as set forth in claim 4 in which said second fold line extends from an inside right angle corner of said trapezoidal main portion of said fourth extension flap to the end of said one parallel side edge of said trapezoidal main portion positioned substantially diagonally thereacross.

6. A carton as set forth in claim 4 in which said first fold line and said second fold line are each in the form of a cut-score line to thereby enable reverse folding thereabout of their respective second and fourth extension flaps.

7. A carton as set forth in claim 4 in which said first extension flap has an outward extension such that the outer edge thereof is spaced apart from the portion of said trapezoidal main portion which is held flatly against the outside surface of said full area flap, and said first extension flap has a corner of its unattached end portion sandwiched between said full-area flap and said fourth extension flap while part of said first extension flap arranged inwardly of said corner cooperates with said full-area flap to sandwich said end portion of said integral glue tab therebetween, said end portion of said glue tab and trapezoidal main portion assuring said first extension flap does not wedge between and unfasten said full-area flap and said fourth extension flap.

8. A carton as set forth in claim 7 in which said first fold line and said second fold line are each in the form of a cut-score line to thereby enable reverse folding thereabout of their respective second and fourth extension fla s.

A carton as set forth in claim 8 and further comprising a fifth extension flap extending from the upper edge of one of said side walls and defining a top wall for said carton, said fifth extension flap having a tuck flap extending from its terminal end for closing said carton.

10. A carton as set forth in claim 7 in which said first extension flap has an approximately rectangular cutout provided in its outer corner which is arranged ad acent said glue tab to assure said glue tab can be more easily moved in position.

11. A carton as set forth in claim 7 made of comparatively inexpensive cylinder board yet providing said high strength bottom wall.

12. A blank being cut and scored and adapted to be assembled to define a resulting carton, said blank comprising, a first pair of walls defining oppositely arranged end walls in said resulting carton, a second pair of walls adapted to be fastened to opposite side edges of 831d end walls and defining a pair of oppositely arranged side walls in said resulting carton, a plurality of cooperating extension flaps extending from the lower edges of said walls and cooperating to define a bottom wall for said result ng carton, said extension flaps comprising, a first extension flap extending from one of said side walls and comprisinga part of the outside surface of said bottom wall of said resulting carton, a second extension flap extending from one of said end walls and being adapted to be fastened to said first extension flap in said resulting carton, a fold line in said second extension flap enabling said first and second flaps and their adjoining walls to be folded in a common plane while securely fastened together, a third full-area extension flap extending from the other of said side walls and having an area substantially equal to the total area of said bottom wall of said resulting carton, with said third extension flap defining the inside surface of said bottom wall, a fourth extension flap extending from the other of said end walls, a glue tab provided as an integral portion of said fourth extension flap and being adapted to be fastened to said third extension flap in said resulting carton, said integral glue tab having an overall length greater than half the width of said bottom wall of said resulting carton to provide a comparatively large glue area, said integral glue tab comprising a substantially rectangular tab having an overall length such that in said resulting carton an end portion thereof is sandwiched between said first entension flap and said full-area flap, and a second fold line in said fourth extension flap enabling said third and fourth extension flaps and their adjoining walls to be flattened in said common plane, said resulting carton being pre-glued and shipped and stored in a flattened condition and easily set up by pushing opposite side edges of the flattened resulting carton substantially toward each other causing said extension flaps to be moved together in an interlocking manner to automatically define said bottom wall and causing the outer corner of said full-area flap arranged adjacent said glue tab to drag across an end wall tending to unfasten said third and fourth extension flaps and the comparatively large glue area of said glue tab and interlocking arrangement of said extension flaps assure complete set up of said resulting carton while providing a high strength bottom wall therein in which said extension flaps remain securely glued together.

13. A blank being cut and scored and adapted to be assembled to define a resulting carton, said blank comprising, a first pair of walls defining oppositely arranged end walls in said resulting carton, a second pair of walls adapted to be fastened to opposite side edges of said end walls and defining a pair of oppositely arranged side walls in said resulting carton, a plurality of cooperating extension flaps extending from the lower edges of said walls and cooperating to define a bottom wall for said resulting carton, said extension flaps comprising, a first extension flap extending from one of said side walls and comprising a part of the outside surface of said bottom wall of said resulting carton, a second extension flap extending from one of said end walls and being adapted to be fastened to said first extension flap in said resulting carton, a fold line in said second extension flap enabling said first and second flaps and their adjoining walls to be folded in a common plane while securely fastened together, a third full-area extension flap extending from the other of said side walls and having an area substantially equal to the total area of said bottom wall of said resulting carton, with said third extension flap defining the inside surface of said bottom wall, a fourth extension flap extending from the other of said end walls, a glue tab provided as an integral portion of said fourth extension flap and being adapted to be fastened to said third extension flap in said resulting carton, said glue ta-b having an overall length greater than half the width of said bottom wall of said resulting carton to provide a comparatively large glue area, said first extension flap having an outward extension approximately equal to half the width of said bottom wall of said resulting carton and said integral glue tab comprising a substantially rectangular tab having an overall length such that in said resulting carton an end portion thereof is sandwiched between the terminal end portion of said first extension flap and said full-area flap, a second fold line in said fourth extension flap enabling said third and fourth extension flaps and their adjoining walls to be flattened in said common plane, and a fifth extension flap extending from the upper edge of one of said side walls and being adapted to define a top wall for said resulting carton, said fifth extension flap having a tuck flap extending from its terminal end for closing said resulting carton, said resulting carton being pre-glued and shipped and stored in a flattened condition and easily set up by pushing opposite side edges of the flattened resulting carton substantially toward each other causing said extension flaps to be moved together in an interlocking manner to automatically define said bottom wall and causing the outer corner of said full-area flap arranged adjacent said glue tab to drag across an end wall tending to unfasten said third and fourth extension flaps and the comparatively large glue area of said glue tab and interlocking arrangement of said extension flaps assure complete set up of said resulting carton while providing a high strength bottom wall therein in which said extension flaps remain securely glued together.

14. A blank being cut and scored and adapted to be assembled to define a resulting carton, said blank comprising, a first pair of walls defining oppositely arranged end walls in said resulting carton, a second pair of walls adapted to be fastened to opposite side edges of said end walls and defining a pair of oppositely arranged side walls in said resulting carton, a plurality of cooperating extension flaps extending from the lower edges of said Walls and cooperating to define a bottom wall for said resulting carton, said extension flaps comprising, a first extension flap extending from one of said side walls and comprising a part of the outside surface of said bottom wall of said resulting carton, a second extension flap extending from one of said end walls and being adapted to be fastened to said first extension flap in said resulting carton, a fold line in said second extension flap enabling said first and second flaps and their adjoining walls to be folded in a common plane while securely fastened together, a third full-area extension flap extending from the other of said side walls and having an area substantially equal to the total area of said bottom wall of said resulting carton, with said third extension flap defining the inside surface of said bottom wall, a fourth extension flap extending from the other of said end walls, a glue tab provided as an integral portion of said fourth extension flap and being adapted to be fastened to said third extension flap in said resulting carton, said glue tab having an overall length greater than half the width of said bottom wall of said resulting carton to provide a comparatively large glue area, said fourth extension flap having a main portion of substantially trapezoidal outline, said integral glue tab having a rectangular outline and having an edge arranged in line with a non-parallel edge of said trapezoidal main portion and an adjoining edge which is common with the outer one of the parallel side edges of said trapezoidal main portion, said rectangular glue tab having a length greater than the length of said one parallel side edge so that an end portion thereof is sandwiched between said first extension flap and said full-area flap in said resulting carton, and a second fold line in said fourth extension flap enabling said third and fourth extension flaps and their adjoining walls to be flattened in said common plane, said resulting carton being pre-glued and shipped and stored in a flattened condition and easily set up by pushing opposite side edges of the flattened resulting carton substantially toward each other causing said extension flaps to be moved together in an interlocking manner to automatically define said bottom wall and causing the outer corner of said full-area flap arranged adjacent said glue tab to drag across an end wall tending to unfasten said third and fourth extension flaps and the comparatively large glue area of said glue tab and interlocking arrangement of said extension flaps assure complete set up of said resulting carton while providing a high strength bottom wall therein in which said extension flaps remain securely glued together.

15. A blank as set forth in claim 14 in which said first fold line and said second fold line are each in the form of a cut-score line to thereby enable reverse folding thereabout of their respective second and fourth extension flaps.

16. A blank as set forth in claim 15 in which said first extension flap has an approximately rectangular cutout provided in its outer corner which is arranged adjacent said glue tab to assure said glue tab can be more easily moved in position upon setting up said resulting carton.

References Cited UNITED STATES PATENTS 2,066,753 1/1937 Weiss 22941 2,677,494 5/1954 Buttery 22939 2,760,709 8/1956 Bruehl et al. 22939 2,914,237 11/1959 Mal mad 2294l 2,918,205 12/1959 Zeitter 22939 X 2,943,780 7/1960 Bolding 229-41 X 3,374,937 3/1968 Wilson 229-41 X DAVIS T. MOORHEAD, Primary Examiner 

